Method for manufacturing a planar resistance heating element

Abstract

Disclosed herein is a manufacturing method of a planar resistance heating element and a planar resistance heating element made using the method. In the manufacturing method of a planar resistance heating element by etching an aluminum foil deposited on an insulating substrate in a desired pattern, printing carbon paste and connecting current input terminals in parallel, the aluminum foil is adapted to undergo a multiple step tempering process to thereby prevent heat deformation. The carbon paste acting as a resistor element is made of electrically conductive carbon, graphite, a resin, a solvent and a hardener which are mixed so as to optimize physical properties of the carbon paste. As a result, prevention of heat deformation of the insulating substrate, uniform heat conductivity, excellent heat-generation effect and easy manufacture may be achieved. In addition, the use of the carbon paste having optimized physical properties as a resistor element results in good heat-generation and near-zero temperature variation.

1. A method for manufacturing a planar resistance heating element, said method comprising:
 a) tempering an aluminum foil deposited on an insulating substrate in a stepwise manner at a temperature of 0 to 40 degree C. for 1.5 to 2.5 hours, thereafter at a temperature of 40 to 70 degree C. for 1.5 to 2.5 hours, thereafter at a temperature of 70 to 100 degree C. for 2.5 to 3.5 hours, and thereafter at a temperature of 100 to 130 degree C. for 14 to 18 hours; 
 b) then etching said aluminum foil in a desired pattern to make a planar resistance heating element; and 
 c) then printing carbon paste and connecting input terminals in parallel to said heating element. 
 
     
     
       2. The manufacturing method of  claim 1 , wherein the tempered aluminum foil is cleaned using a cleansing solution of pH 10 to 12, and dried at a temperature of 50 to 65° C.